Vehicle and fresh air intake for a vehicle

ABSTRACT

An air intake for a vehicle that facilitates air transfer from an ambient environment outside the vehicle to a vehicle space is provided. The air intake inhibits liquid transfer from the ambient environment to the vehicle space. The air intake includes a housing having an inlet for receiving air from the ambient environment, and an outlet in communication with the inlet. The outlet is disposed in an upper portion of the housing. A blocking member is disposed within the housing adjacent the inlet for preventing upward fluid flow from the inlet directly to the outlet, thereby inhibiting liquid flow through the outlet and into the vehicle space. A portion of the air intake housing is configured for attachment to a vehicle window, and the inlet is configured to be disposed along one edge of the window.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a division U.S. application Ser. No. 10/605,182filed Sep. 12, 2003, which is hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a vehicle and a vehicle fresh airintake that inhibits water ingestion.

2. Background Art

A vehicle may use ambient air from outside of the vehicle for a numberof purposes. For example, vehicle radiators utilize ambient air totransfer heat from the engine coolant, to keep the engine fromoverheating. Outside air may also be mixed with fuel and supplied to theengine. Moreover, outside air may be utilized by heating, ventilation,and air conditioning systems (HVAC), which in turn maintain the climateof the vehicle passenger compartment. Of course, other vehicle systemsmay utilize outside air for a number of reasons, including the coolingof electrical components. When electrical components overheat, theirperformance may degrade or their life span may be compromised. Thus,adequate cooling for electrical components is an important considerationin vehicle design.

One example of a vehicle system that requires adequate cooling a bank ofbatteries used to power an electric vehicle. Other types of vehiclearchitectures—e.g., hybrid electric vehicles (HEV) and fuel cellvehicles—may similarly have power generating systems that emit largequantities of heat. Thus, it may be desirable to provide ambient aireither directly to these systems, or to an HVAC that may further lowerthe air temperature to more effectively cool the vehicle system. Oneexample of a fresh air intake used to take in ambient air to cool a bankof batteries in an electric vehicle is found in U.S. Pat. No. 5,392,873,issued to Masuyama et al. on Feb. 28, 1995. Masuyama et al. describes astructure for holding the batteries that includes an air intake passage.The air intake for the battery compartment is disposed beneath thevehicle, with an inlet facing upward toward the vehicle undercarriage.Because the inlet is disposed beneath the vehicle, liquid and soliddebris from the road surface may enter the air intake. The air intake isprovided with a chamber where liquid and other foreign material may betrapped prior to entering the battery compartment. The location of theair intake below the vehicle may increase the likelihood of taking inroad debris.

Thus, there exists a need for a vehicle air intake configured tofacilitate air transfer from an ambient environment outside the vehicleto a vehicle space, such that the air intake can be disposed on aportion of the vehicle away from the surface of the road, therebyreducing or eliminating the intake of road debris, while also inhibitingthe transfer of water from the air intake to the vehicle space.

SUMMARY OF THE INVENTION

Therefore, an air intake for a vehicle configured to facilitate airtransfer from an ambient environment outside the vehicle to a vehiclespace is provided. The air intake includes a housing, a portion of whichis configured for attachment to a vehicle window. The housing includesan inlet which is configured to be disposed along one edge of thewindow.

The invention also provides an air intake for a vehicle configured tofacilitate air transfer from an ambient environment outside the vehicleto a vehicle space, while inhibiting liquid transfer from the ambientenvironment to the vehicle space. The air intake includes a housinghaving an inlet for receiving air from the ambient environment, and anoutlet in communication with the inlet. The outlet is disposed in anupper portion of the housing and facilitates air transfer from thehousing to the vehicle space. A first dam is disposed within the housingadjacent the inlet for preventing upward fluid flow from the inletdirectly to the outlet, thereby inhibiting liquid flow through theoutlet.

The invention further provides an air intake for a vehicle configured tofacilitate air transfer from an ambient environment outside the vehicleto a vehicle space, while inhibiting liquid transfer from the ambientenvironment to the vehicle space. The air intake includes an inlet forreceiving air from the ambient environment. A first chamber is adjacentthe inlet and in communication with the inlet. The first chamber ispartially defined by an upper boundary configured to prevent upwardfluid flow out of the first chamber. A plurality of vanes are disposedadjacent to each other and in relation to the inlet such that the vanesdirect the fluid flow from the inlet to the first chamber. A secondchamber is adjacent the first chamber and has a common walltherebetween. The second chamber includes an upper portion and a lowerportion; the lower portion is open to the first chamber. An outlet is incommunication with the inlet. The outlet is disposed adjacent the secondchamber upper portion, thereby facilitating air transfer from the secondchamber to the vehicle space.

The invention also provides a vehicle having a window, a batterycompartment, and an air intake configured to facilitate air transferfrom an ambient environment outside the vehicle to the batterycompartment, while inhibiting liquid transfer from the ambientenvironment to the battery compartment. The air intake includes ahousing disposed adjacent the window. The housing includes an inletdisposed along one edge of the window for receiving air from the ambientenvironment. The housing also includes an outlet in communication withthe inlet. The outlet is disposed in an upper portion of the housing andfacilitates air transfer from the housing to the battery compartment. Afirst dam is disposed within the housing adjacent the inlet forpreventing upward fluid flow from the inlet directly to the outlet,thereby inhibiting liquid flow through the outlet.

The above objects, features, and advantages of the present invention arereadily apparent from the following detailed description of the bestmode for carrying out the invention when taken in connection with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial fragmentary side view of a vehicle including an airintake in accordance with the present invention;

FIG. 2 is a sectional view of the air intake shown in FIG. 1, takenthrough line 2—2;

FIG. 3 is a perspective view of a first portion of a housing of the airintake;

FIG. 4 is a perspective view of a portion of an alternative embodimentof the air intake shown in FIGS. 1–3;

FIG. 5 is a partial fragmentary view of the air intake shown in FIGS.1–3 indicating the direction of air flow within the housing;

FIG. 6 is a perspective view of a second portion of the air intakehousing; and

FIG. 7 is a partial fragmentary perspective view of a portion of avehicle including an air intake, air conditioning system, and a batterycompartment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

FIG. 1 shows a portion of a vehicle 10 having an air intake 12 inaccordance with the present invention. The air intake 12 is attached toa rear quarter window 14 of the vehicle 10. Although the air intake 12may be located adjacent the window 14, it may be placed in otherconvenient locations, such as adjacent a vehicle body panel.

A sectional view of the air intake 12, taken through section line 2-2 inFIG. 1, is shown in FIG. 2. As seen in FIG. 2, the air intake 12includes a housing 16, having a first portion 18 and a second portion20. The first portion 18 includes an inlet 22 that is open to an ambientenvironment outside the vehicle 10. The second portion 20, includes anoutlet 24 in communication with the inlet 22. As explained more fullybelow, ambient air from outside the vehicle enters the inlet 22, flowsthrough the housing 16, and out of the outlet 24 to a vehicle space. Inthe embodiment shown in FIGS. 1–2, the inlet 22 is disposed adjacent oneedge 26 of the window 14. Within the housing 12, there are first andsecond chambers 28, 30 having a wall 32 disposed therebetween.

FIG. 3 shows an isolated view of the first housing portion 18. Aplurality of vanes 34 are disposed adjacent to each other, and aredisposed in relation to the inlet 22 such that they direct the flow ofair from the inlet 22 into the first chamber 28. Because the first andsecond housing portions 18, 20 cooperate to form the first and secondchambers 28, 30 the first chamber 28 is not visible in FIG. 3.Directional arrows are shown in FIG. 3 to indicate the general flow ofair from the intake 22. Although the vanes 34 shown in FIG. 3 arerelatively short and generally straight, it is contemplated that theymay be configured differently to have a greater effect on the air flow.

For example, as seen in FIG. 3, the vanes 34 extend a relatively shortdistance into the first chamber 28; however, vanes may be configured toextend further into the first chamber, or alternatively, not at all. Inaddition to directing the air into the housing, vanes, such as the vanes34, may also breakup a water stream entering an air intake inlet. Vanesmay be configured to provide an almost horizontal air flow into ahousing, or may be angled to direct the air flow either up or down. Asused here and throughout, directions such “up” and “down” refer to anair intake as installed in a vehicle. Still other vane configurationsinclude curved vanes, or a combination of curved and straight portions.

One such example is illustrated in FIG. 4, which shows a portion of anair intake 36 having a plurality of vanes 38 disposed adjacent an inlet40, which is on the opposite side of the air intake 36 as shown in FIG.4. As in the embodiment shown in FIGS. 1–3, the vanes 38 direct the flowof air from the inlet 40 into a first chamber 42, only a portion ofwhich is shown in FIG. 4. The vanes 38 increase in length as they nearan upper portion 44 of the air intake 36. In addition, the vanes 38 arecurved so as to direct air flow from the inlet 40 in a generallydownward direction. As explained more fully below, this helps inhibitwater taken in from the ambient environment outside the vehicle fromflowing into the vehicle space along with the air.

Returning to FIG. 3, it is seen that the vanes 34 are not curved likethe vanes 38, shown in the embodiment in FIG. 4. Despite this, at leastsome of the air flowing into the first chamber 28 of the air intake 12will flow in a generally downward direction prior to entering the secondchamber 30; this is illustrated in FIG. 5. The second chamber 30includes a lower portion 46 that is open to the first chamber 28. Thesecond chamber 30 also includes an upper portion 48 which is adjacentthe outlet 24. Thus, as shown in the cutaway in FIG. 5, air from thefirst chamber 28 moves in a generally downward direction into the secondchamber 30 before moving upward and through the outlet 24. In this way,water which may enter the inlet 22 along with air from the ambientenvironment outside the vehicle, will be forced toward the bottom of thehousing 16, and will be inhibited from reaching the outlet 24 andflowing into a vehicle space. Water which is forced to the bottom of thehousing 16 may exit the air intake 12 through the inlet 22, or through adrain hole 49, provided in the first housing portion 18, see FIG. 3.

In order to direct the flow of air from the inlet 22 in a generallydownward direction, fluid flow in the first chamber 28 is forced intothe lower portion 46 of the second chamber 30. This is accomplished byusing a first dam 50, shown in FIG. 3. The first dam 50 is an upperboundary which partially defines the first chamber 28. The first dam 50prevents the upward flow of fluid out of the first chamber 28. The wall32 forms a second dam which is adjacent to the inlet 22 and the firstdam 50. The first and second dams 50, 32 cooperate to force air from theinlet 22 in a generally unshaped flow path toward the outlet 24, whichseparates water from the air. In the embodiment shown in FIG. 3, thefirst and second dams 50, 32 form a unitary blocking structure 52 thatis integrally molded with the first housing portion 18.

As seen in FIG. 2, the second dam 32, and indeed the entire blockingstructure 52, extend from an inner surface 54 of the first housingportion 18 toward the second housing portion 20. To help prevent fluidfrom flowing between the blocking structure 52 and the second housingportion 20, a channel 56 is provided in the second housing portion 20.As shown in FIGS. 2 and 6, the channel 56 is raised up from an innersurface 58 of the second housing portion 20. Of course, a channel, suchas the channel 56, may be formed under the inner surface of a housing. Asealing material, such as foam, adhesive or the like may be disposed inthe channel 56 to further prevent fluid from flowing between theblocking structure 52 and the second housing portion 20.

Of course, a blocking structure, such as the blocking structure 52,could be integral with the second housing portion 20, or alternatively,it need not be integral with the housing at all. For example, individualdams could be manufactured separately and placed in grooves or channelsprior to assembling the housing. The housing could be configured toaccommodate a number of different dams and/or blocking structures,thereby allowing a degree of flexibility in the manufacturing of an airintake. As desired, different sealing materials could be used to helpprevent fluid flow past the dams.

The housing 16 described herein, includes two housing portions 18, 20.Of course, a housing, such as the housing 16, may include a singleportion, or more than two portions, as desired. With regard to thehousing 16, it is contemplated that the two portions 18, 20 may be madefrom different materials, and joined with a polymeric adhesive, such asurethane. To accommodate the use of a urethane adhesive, the secondhousing portion may be configured with standoff pins 59 to maintain agap between the two housing portions 18, 20 after they are assembled.Alternatively, the housing portions 18, 20 may be joined with othertypes of adhesives, or even mechanical fasteners, such as screws orrivets. As seen in FIG. 6, the second housing portion 20 includesflanges 61, which are used in conjunction with locating pins 63 on thefirst housing portion 18, see FIG. 3.

The use of different materials for each housing portion may accommodatethe different functions of the two housing portions 18, 20. For example,the first housing portion 18, has an outer surface 65 exposed to theambient environment, see FIG. 2. In addition, the outer surface 65 isvisible from the vehicle exterior, where it may be desirable to presentan aesthetically pleasing appearance. Thus, an abrasion resistantpolymer, such as a polycarbonate, which may also provide an appearancefinish, may provide the desired combination of properties for the firsthousing portion 18.

Unlike the aesthetic considerations which may be present for thematerial selection of the first housing portion 18, different propertiesmay be more important for the second housing portion 20. For example,strength may be a primary consideration, since the second housingportion 20 is not visible from the vehicle exterior. Hence, anacrylonitrile butadiene styrene (ABS) or polypropylene (PP) may be wellsuited for the second housing portion 20. Of course, the foregoing aremerely examples of some of the materials from which the housing 16 maybe made. Different considerations may be present for various embodimentsof the present invention, and other polymers or even other classes ofmaterials may be desired for a particular application.

As briefly discussed above, an air intake, such as the air intake 12,may be used to transfer air from an ambient environment outside avehicle to a vehicle space. The air may flow directly through the airintake and into the vehicle space, or it may flow into some type of airconditioning system prior to reaching the vehicle space. One such airconditioning system is described in copending U.S. patent applicationSer. No. 10/605,179, entitled “Cooling System for a Vehicle Battery”,filed on Sep. 12, 2003, and hereby incorporated herein by reference.FIG. 7 shows an interior portion 60 of the vehicle 10. The outlet 24 ofthe air intake 12 is attached to a duct 62 which transfers air from theoutlet 24 to an air conditioning system 64.

The air conditioning system 64 draws fresh air in through the inlet 22with a blower fan, and outputs cooled air through a duct 66 and into abattery compartment 68. Supplying the battery compartment 68 with coolair from the air conditioning system 64, will help cool battery assembly70, thereby helping to extend its life. Of course, air taken in from anair intake, such as the air intake 12, may be routed to any desiredvehicle space, or into another type of air conditioning system—e.g., anair conditioning system used to cool the vehicle passenger compartment.An example of an air conditioning system that can be used to cool both abattery compartment and a passenger compartment is described incopending U.S. patent application Ser. No. 10/605,181, entitled “VehicleCooling System”, filed on Sep. 12, 2003, and hereby incorporated hereinby reference.

As described above, the air intake 12 helps to inhibit water taken infrom the ambient environment outside the vehicle 10 from flowing throughthe outlet 24. Thus, the air conditioning system 64 receives little orno water from the air intake 12. In addition, because the air intake 12may be disposed high up on a vehicle away from the surface of the road,it is unlikely that road debris or other solid matter will enter theinlet 22. If, however, some solid matter does enter the air intake 12,it will be forced downward with the air flow toward the bottom of thehousing 16, where it is free to exit the air intake 12 through the inlet22. Although it may be unlikely that any solid matter would be carriedupward and out of the outlet 24, additional protection is easily addedto the air intake 12. If desired, one or more air-permeable barriers,such as screens, may be added to the air intake 12 to prevent solids,and to some extent liquids, from reaching the vehicle space. Forexample, returning to FIG. 2, screens 72, 74 are shown adjacent theinlet 22 and the outlet 24, respectively. Of course, screens, or otherair-permeable barriers, may be placed at different locations on or inthe air intake 12 as desired.

While embodiments of the invention have been illustrated and described,it is not intended that these embodiments illustrate and describe allpossible forms of the invention. Rather, the words used in thespecification are words of description rather than limitation, and it isunderstood that various changes may be made without departing from thespirit and scope of the invention.

1. A vehicle, comprising: a window; a vehicle space; and an air intakeincluding a housing having an inlet disposed adjacent the window forreceiving air from an ambient environment outside the vehicle, and anoutlet in communication with the inlet, the outlet being disposed in anupper portion of the housing and facilitating air transfer from thehousing to the vehicle space, the air intake further including a firstdam disposed within the housing adjacent the inlet for preventing upwardfluid flow from the inlet directly to the outlet, thereby inhibitingliquid flow through the outlet.
 2. The vehicle of claim 1, wherein theair intake further includes an air-permeable barrier disposed adjacentthe outlet for inhibiting passage of non-gases through the outlet. 3.The vehicle of claim 1, wherein the vehicle space includes a batterycompartment.
 4. The vehicle of claim 1, wherein the air intake furtherincludes a plurality of vanes disposed adjacent each other and disposedin relation to the inlet such that the vanes direct fluid flow from theinlet into the housing.
 5. The vehicle of claim 4, wherein at least someof the vanes are configured to direct fluid flow from the inlet into thehousing in a generally downward direction.
 6. The vehicle of claim 1,wherein the air intake further includes a second dam disposed within thehousing adjacent the inlet and the first dam, and configured tocooperate with the first dam to direct at least some fluid flow from theinlet in a generally downward direction.
 7. The vehicle of claim 6,wherein the first and second dams cooperate to force at least some fluidflow from the inlet in a generally u-shaped flow path toward the outlet.8. A vehicle, including: a vehicle space; and an air intake including,a) an inlet for receiving air from an ambient environment outside thevehicle, b) a first chamber adjacent the inlet and in communication withthe inlet, the first chamber being partially defined by an upperboundary configured to prevent upward fluid flow out of the firstchamber, c) a plurality of vanes disposed adjacent to each other and inrelation to the inlet such that the vanes direct fluid flow from theinlet to the first chamber, d) a second chamber adjacent the firstchamber and having a common wall therebetween, the second chamberincluding an upper portion and a lower portion, the lower portion beingopen to the first chamber, and e) an outlet in communication with theinlet, and disposed adjacent the second chamber upper portion, therebyfacilitating air transfer from the second chamber to the vehicle space.9. The vehicle of claim 8, wherein at least some of the vanes areconfigured to direct fluid from the inlet into the first chamber in agenerally downward direction.
 10. The vehicle of claim 8, wherein thevehicle space includes a battery chamber.
 11. The vehicle of claim 8,wherein the air intake further includes an air-permeable barrierdisposed adjacent the inlet for inhibiting passage of non-gases from theambient environment into the first chamber.
 12. The vehicle of claim 8,wherein the air intake further includes an air-permeable barrierdisposed adjacent the outlet for inhibiting passage of non-gases throughthe outlet.
 13. The vehicle of claim 8, wherein the air intake furtherincludes a housing including first and second portions, the firstportion including the inlet, the second portion including the outlet,and the first and second portions cooperating to form the first andsecond chambers.
 14. The vehicle of claim 13, further comprising awindow, and wherein the first housing portion is configured forattachment to the window, and the inlet is configured to be disposedalong one edge of the window.